The Japan Kaikaku Experience is a best practice benchmarking tour of world class lean manufacturing companies. It is a full-immersion experience in the lean culture. The Kaikaku tour is designed to open our eyes, broaden our horizons, deepen our understanding of lean practices and ultimately transform our attitudes about what is possible through kaizen (continuous improvement).

What Will We Do on the JKE?

We observe the actual workplace (gemba) up close. We learn from the leaders of companies who have gone through lean transformations. Each day begins with a review of the day's highlights and ends with a reflection and sharing of what each participant learned. We create time for additional instruction as needed by our consultants and guest speakers which includes retired Toyota executives. During the course of travel between the tour locations we will see some sites and learn about Japan's history and culture, and how this influences the application of lean principles.

Which Companies Will We Visit?

We have built relationships with over 100 companies in Japan who we believe are world leaders in doing kaizen. We visit Toyota factories, logistics centers, suppliers as well as other companies in diverse industries. These companies have been doing kaizen in some form between 5 and 50 years. The companies we visit have integrated the management philosophies into continuous daily improvement. We select each company for their unique stories and strengths. Each company faces its own set of challenges and has adapted Toyota Production System (TPS) principles faithfully but flexibly.

What Will We See?

We see the philosophy, the tools and systems of lean (the Toyota Production System) in action. Each company demonstrates excellence in the fundamentals such as 5S, visual management, employee engagement, problem solving, standardized work, quality mindset, focus on safety, continuous flow, intelligent automation and much more. It is a sign of their commitment to Lean thinking that our host companies are willing to show us the best of what they have done. By sharing their best practices with others, these companies are motivated and challenged to rise to a higher level of performance.

What Will We Learn?

The companies we visit have integrated the management philosophies with day to day execution of improvement activity. The results that they have generated over the years are dramatic. As an example, Toku Manufacturing is able to run nearly 300 machines with 35 people, all because of the advanced level of Jidoka (Low Cost Intelligent Automation) that they have achieved. The employees at most of the companies we visit generate and implement more than one improvement idea per month. We will learn not only about lean tools and systems but also how these companies have struggled and succeeded to implement and sustain changes to their culture.

Why Go to Japan?

We go to Japan because there is no other place in the world today where so many excellent companies can be visited in such depth and efficiency in such short time period. Due to an accident of history, Japanese industry adopted the ideas of Henry Ford, Dr. Edwards Deming and others much more thoroughly and rapidly then most Western countries over the past 60 years. For a country with such a small landmass there are an amazing number of world class companies. This fact combined with the excellent high speed rail and transport system makes travel within Japan very smooth.

The partners of Kaizen Institute include expatriates who have lived in Japan for many years, speak the language fluently and understand the culture. This has allowed us to build strong relationships with a excellent companies based on trust and the demonstration of humility. With every group of visitors from overseas who to come to Japan with the sincerity to learn, our relationship with these companies improves.